Systems and methods for forming openings in water soluble packet

ABSTRACT

Systems and methods to form openings in water soluble packets are described. The system includes a packet forming assembly to form water soluble packets, and a laser to form one or more openings in the water soluble packets. The method includes forming openings in the water soluble packets with a laser. The openings permit air to escape from the packets. By allowing air to escape, the water soluble packets have improved packaging characteristics. The water soluble packets are packed more tightly with a product.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Nonprovisional applicationSer. No. 18/089,032, filed Dec. 27, 2022 which is a continuation of U.S.Nonprovisional application Ser. No. 17/329,067, filed May 24, 2021 whichis a continuation of U.S. Nonprovisional application Ser. No.14/179,878, filed Feb. 13, 2014, which claims the benefit of U.S.Provisional Patent Application 61/764,196 filed Feb. 13, 2013, and whichis hereby incorporated by reference.

FIELD OF INVENTION

The present invention relates to systems and methods for formingopenings in water soluble packets involving the use of a laser.

BACKGROUND OF INVENTION

Water soluble packets, also commonly referred to as pouches or sachets,provide a single dose of a product in one convenient unit. The watersoluble packets include a water soluble film sealed around apre-measured amount of the product. During exposure or contact withwater, the film dissolves and the product mixes with the water. Thewater soluble packets provide many benefits to the consumer. The watersoluble packets arc pre-measured, and thus avoid any measuring by theconsumer. The product is contained by the film, and it not prone tospilling.

The water soluble packets are commonly used with dishwasher and laundrydetergents. During a wash cycle, the water soluble film dissolves whenexposed to the wash liquid allowing the detergent to mix with the washliquid. The water soluble packets may also be used in any of a varietyof different applications and contain any of a variety of differentproducts. For example, herbicides, fertilizers, lawn chemicals,rinse-aids, cleaners, etc. may all be sealed within the water solublepackets.

Conventional water soluble packets are formed by using a drum havingrows of cavities on its exterior surface. A base or bottom layer offilm, such as a polyvinyl alcohol (PVA) film, is applied over thecavities. A vacuum from inside of the drum draws the base layer of filminto the cavities to form a receptacle to receive the product. Aspecified amount of the product is next metered onto the base layer offilm. A lid or an upper layer of film, such as additional PVA film, isthen sealed over the base layer of the film. The product is now sealedinside of a combination of the base layer and the lid layer of films.Rows and rows of water soluble packets are formed as part of acontinuous process. As the drum rotates, individual water solublepackets arc cut from the rows of water soluble packets. Such processesand equipment are described in U.S. Pat. No. 3,218,776, which is herebyincorporated by reference.

During the filling and sealing process, air becomes trapped inside ofthe packet with the product. The air forms an air bubble or an airpocket inside of the sealed water soluble packet. The air bubble or airpocket may cause inadvertent rupture of the water soluble packet and isnot desirable from an aesthetic or packaging perspective.

In order to get the air out of packet, a water mist is typically sprayedonto the sealed water soluble packet by a mister. The water mist createspassages in the film of the water soluble packet to allow air trapped inthe laundry packet to escape. Unfortunately, the water may also causemuch of the film to discolor, which may not be cosmetically desirablefrom a consumer's or a retailer's perspective. Further, the watersoluble packets may also become sticky and adhere to one another afterbeing sprayed with the water mist. This causes problems in automatedfilling processes, which direct the water soluble packets intocontainers for retail sale. In these automated filling processes, thecontainers may be filled by weight, and multiple water soluble packetssticking together may interfere with such automated filling processes.

SUMMARY OF INVENTION

Systems and methods for forming openings in water soluble packetsinvolving the use of a laser are herein described. The laser forms theopenings to vent the water soluble packets. The openings provide for theescape or release of air trapped in the water soluble packets. The laseralso forms the openings to assist in the filling of the water solublepacket with detergent or other product. The laser burns openings intothe water soluble film that forms the water soluble packet.

The openings provide a number of improvements in the manufacturingprocess for water soluble packets and the resulting water solublepackets. First, the laser openings do not discolor the entire film ofthe water soluble packet. Second, the laser openings do not make thewater soluble packets sticky, which is a problem associated with the useof a conventional water mister. Further, the laser openings, whenapplied in a pre-fill stage, assist in forming the water soluble packetwith several beneficial aesthetic features that may be more desirable toconsumer. The product in such water soluble packets is more tightlypacked with fewer wrinkles in the film as compared to conventionalpackets. Further, the water soluble packets formed using the laserprocesses described herein are not generally pliable and do not exhibita loose feel common to conventional water soluble packets.

The openings may include holes, perforations, voids, vents, etc. in thefilm. The laser burns the openings in the films. The openings permit airto escape from the packets. During the manufacturing process, air may betrapped inside of the packet with the product. The openings provide forthe trapped air to escape or vent. The air trapped in the water solublepacket is generally under pressure, and the openings allow the interiorof the water soluble packet to equilibrate in pressure with theatmosphere. By allowing air to escape, the water soluble packet hasimproved packaging characteristics. The water soluble packets are packedmore tightly with product. Further, the film does not have bubbles orloose folds of the film. Also, the packets arc not sticky or mostlydiscolored. Further, the packets tend to have a uniform and consistentappearance. These characteristics may be desirable to a consumer orretailer.

The laser may be configured to form the openings at any of a variety ofstages during the industrial manufacture of the water soluble packets.During the manufacturing process, the product is filled into cavitieswhich are lined with a base layer of the film. The cavities are in theexterior surface of a rotating drum. After the filling, a lid layer offilm is sealed to the base layer over the product.

The laser may form the openings at a pre-fill stage or at a post-fillstage in the manufacturing process of the water soluble packets. In afirst pre-fill process, the laser forms the openings after the base filmis positioned over or drawn into the cavities of the drum and beforeadding the product to the cavities. In a second pre-fill process, thelaser forms the openings before the base film is positioned over thecavities. For example, the laser forms the openings in the base film asthe base film is unrolled. In a third pre-fill process, the laser formsthe openings in the lid film before the lid film is sealed to the basefilm. For example, the laser forms the openings in the lid film as thelid film is unrolled.

The laser may also form openings in the sealed packets of product, i.e.,at a post-fill stage. For example, the laser may be positioned over anoutput or take away conveyor and direct pulses to the sealed packets.

The laser forms the openings as part of a continuous manufacturingprocess, i.e., the laser forms the openings while the film or watersoluble packets are moving. Typically, the films or water solublepackets are not intermittently slowed or stopped in order to form theopenings with the laser. As such, the use of the laser does not slowdown production rates of the water soluble packets.

The laser may also be used with or integrated into both horizontal andvertical form fill seal machines.

In one aspect, a system to form openings in water soluble packets isdescribed. The system includes a packet forming assembly to form watersoluble packets. The packet forming assembly includes one or morecavities, a base film supply roll that supplies a base film to cover theone or more cavities, a feed hopper meters an amount of a product intothe one or more cavities over the base film, and a lid film supply rollsupplies a lid film that is sealed to the base film. A laser forms oneor more openings in the water soluble packets.

In another aspect, a method of forming openings in water soluble packetsis described. The method includes providing a packet forming assembly toform water soluble packets. The packet forming assembly comprises one ormore cavities. The method includes covering the one or more cavitieswith a base film. The method includes feeding an amount of a productinto the one or more cavities over the base film. The method includessealing a lid film to the base film to form the water soluble packets.The method includes forming openings in the water soluble packets with alaser.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic view of multiple configurations of thelaser-assisted water soluble packet forming system.

FIG. 2 is a perspective view of the packet forming assembly.

FIG. 3 is a perspective view of the first configuration of thelaser-assisted water soluble packet forming system.

FIG. 4 is a perspective view of the second configuration of thelaser-assisted water soluble packet forming system.

FIG. 5 is a perspective view of the third configuration of thelaser-assisted water soluble packet forming system.

FIG. 6 is a perspective view of the fourth configuration of thelaser-assisted water soluble packet forming system.

FIG. 7 is a perspective view of the water soluble packet.

FIG. 8 is close-up view of the drum and its cavities.

FIG. 9 is a schematic view of the laser with a horizontal form fill sealmachine.

FIG. 10 is a perspective view of the laser with a vertical form fillseal machine.

DETAILED DESCRIPTION OF INVENTION

FIG. 1 is a schematic view of multiple configurations of alaser-assisted water soluble packet forming system 10, which is used toform water soluble packets 50. An example of the water soluble packet 50is shown in FIG. 7 . The system 10 forms openings 90 in the watersoluble packets 50. The openings 90 are formed by a laser 410. As shownin FIG. 1 , the laser 410 may be positioned at any of a number ofdifferent alternate positions about the system 10.

The water soluble packets 50 include a product 60 scaled between a baselayer 70 and a lid layer 80. The base layer 70 is formed from a basefilm 200, while the lid layer 80 is formed from a lid film 300. Theopenings 90 include holes, perforations, voids, vents, etc. in either orboth of the base layer 70 and the lid layer 80. As described below, thelaser 410 may direct its pulses at any of the base film 200, the lidfilm 300, and/or the sealed water soluble packets 50. Depending upon theset-up, the laser 410 burns the openings 90 in any or all of the baselayer 70, lid layer 80, base film 200, or lid film 300.

FIG. 2 is a perspective view of a packet forming assembly 100, whichincludes a rotating drum 110 operatively engaged to a motor 120 forrotation of the drum 110. The packet forming assembly 100 forms thewater soluble packets 50. The drum 110 includes a plurality of cavities130. A bulk amount of the product 60 is placed in a feed hopper 150,which is generally positioned above the drum 110. As the drum 110rotates, the feed hopper 150 meters an amount of the product 60 into thecavities 130 on top of the base film 200. The lid film 300 is sealed tothe base film 200, and the water soluble packets 50 are separated.

The base film 200 is directed to the drum 110 from the base film supplyroll 220. A base film roller 230 presses the base film 200 against asurface 115 of the drum 110. The base film 200 generally covers aplurality of the cavities 130. Guide rollers 240 and 242 assist indirecting and transferring the base film 200 to the drum 110.

The lid film 300 is directed to the drum 110 from the lid film supplyroll 320. A lid film roller 330 presses the lid film 300 against thebase film 200. A guide roller 340 assists in directing and transferringthe lid film 300 to the drum 110.

The drum 110 includes multiple rows 142 of the cavities 130. Generally,the surface 115 of the drum 110 is covered with the cavities 130. Thelaser 410 may simultaneously pulse groups 144 of the cavities 130. Thegroups 144 may cover multiple rows 142 of the cavities 130.

With reference to FIGS. 1 and 8 , each of the cavities 130 includes avacuum opening 133 that is in fluidic communication with a vacuumpassage 136. The packet forming assembly 100 draws a vacuum through thevacuum passage 136 and the vacuum opening 133.

With reference to FIG. 1 , the packet forming assembly 100 includes acutting assembly 180 to separate the water soluble packets 50 from eachother. The cutting assembly 180 may include a vertical cutter 183 tomake vertical separation cuts and a horizontal cutter 186 to makehorizontal separation cuts. After the water soluble packets 50 areseparated, the drum 110 drops the water soluble packets 50 onto a takeaway conveyor 190.

With continued reference to FIG. 1 , a laser assembly 400 includes thelaser 410 to form the openings 90 in the water soluble packets 50. Thelaser assembly 400 also includes a controller 420 and an encoder 430.The controller 420 and the encoder 430 register and time the pulses fromthe laser 410 to strike the base layer 70, lid layer 80, base film 200,and/or the lid film 300 at the appropriate interval and time.

The laser 410 may be integrated with the packet forming assembly 100 inany of a variety of configurations or positions. As described below ingreater detail, the laser 410 may form the openings 90, shown in FIG. 7, at a pre-fill stage or a post-fill stage in the packet formingprocess. Four exemplary configurations of the system 10 are describedbelow and are referred to herein as configurations 10 a, 10 b, 10 c, and10 d. Of course, one or more lasers 410 may be simultaneously employedat any of the configurations or positions. In summary, FIG. 3 shows aperspective view of the first configuration 10 a of the system 10, whichforms the openings 90 when the base film 200 is over or drawn into thecavities 130. FIG. 4 shows a perspective view of the secondconfiguration 10 b, which forms the openings 90 in the sealed watersoluble packets 50 after the water soluble packets 50 are formed on thedrum 110 and separated by the cutting assembly 180. FIG. 5 shows aperspective view of the third configuration 10 c, which forms theopenings 90 in the lid film 300 before the lid film 300 is sealed to thebase film 200. FIG. 6 shows a perspective view of the fourthconfiguration 10 d, which forms the openings 90 in the base film 200before base film 200 reaches the drum 110.

With reference to FIG. 3 , the first configuration 10 a forms theopenings 90 when the base film 200 is over or drawn into the cavities130. The first configuration 10 a forms the openings 90 at a pre-fillstage. The laser 410 may form openings 90 in the base film 200, whilethe base film 200 is positioned over the drum 110 or after the base film200 has been drawn into the cavities 130 by the vacuum. In this aspect,the openings 90 are formed before the product 60 is added to the basefilm 200. The laser 410 is positioned proximate to the drum 110, and thelaser 410 is focused toward the individual cavities 130 of the drum 110.The drum 110 provides the vacuum through the vacuum passage 136 thatconforms the base film 200 to the drum 110 and into the individualcavities 130. Air is drawn into the vacuum passage 136 through thevacuum opening 133 in the bottom of the cavity 130. The vacuum draws andstretches the base film 200 into the individual cavities 130. The basefilm 200 forms a receptacle shape in the individual cavities 130 toreceive the product 60. Before the product 60 is added to the base film200 positioned in the cavities 130, the laser 410 forms the openings 90in the base film 200. Notably, the openings 90 are formed by the laser410 after the base film 200 has been stretched into the cavities 130 bythe vacuum of the drum 110. The openings 90 are formed in the base film200 after the base film 200 has been stretched, so the openings 90 willgenerally maintain their dimension as the base film 200 is not generallyfurther stretched during the formation of the water soluble packet 50.

In this aspect, the vacuum is also drawing air through the openings 90in the film, which sucks the product 60 into the base film 200. Theproduct 60 may be deposited on the base film 200 in the cavities 130while the vacuum force is drawing the base film 200 into the cavity 130and air is passing through the openings 90 and into the vacuum opening133. This assists in increasing the density of the product 60 within thepacket 50. The product 60 in such water soluble packets 50 is moretightly packed with fewer wrinkles in the film as compared toconventional packets. Without the openings 90 and the drawing of airthrough the openings 90 by the vacuum, the water soluble packet 50 willhave a softer feel and the product 60 will be more loosely contained inthe water soluble packet 50.

With reference to FIG. 4 , the second configuration 10 b forms theopenings 90 in the sealed water soluble packets 50 after the watersoluble packets 50 are formed on the drum 110 and separated by thecutting assembly 180. The second configuration 10 b forms the openings90 at a post-fill stage. The laser 410 may be positioned to formopenings 90 in the sealed water soluble packets 50 after the watersoluble packets 50 are formed on the drum 110 and separated by a cuttingassembly 180. In this aspect, the openings 90 are formed after the lidfilm 300 and base film 200 are sealed together to contain the product60. The laser 410 may be positioned over the take away conveyor 190. Thelaser 410 may be focused on any portion of the water soluble packet 50.

With reference to FIG. 5 , the third configuration 10 c forms theopenings 90 in the lid film 300 before the lid film 300 is sealed to thebase film 200. The third configuration 10 c also forms the openings 90at the pre-fill stage. The laser 410 may form the openings 90 in the lidfilm 300 that forms the packet 50. The laser 410 may be positioned toform openings 90 in the lid film 300 before the lid film 300 reaches thedrum 110. The laser 410 is positioned proximate to the lid film supplyroll 320. As the sheet of the lid film 300 is unrolled and directed tothe drum 110, the laser 410 may form the openings 90. One or more lasersmay be configured to intermittently form openings 90 in the entire widthof lid film 300 used to cover the cavities 130. In this aspect, theopenings 90 may be formed in portions of the lid film 300 which willbecome the sides or a periphery of the finished water soluble packet 50.These areas of the lid film 300 are subjected to less stretching thanthe areas of the base film 200, which will become the central portionsof the water soluble packet 50. By forming the openings 90 at the sidesor periphery, the openings 90 are not generally stretched during thesealing process, and the openings 90 maintain their desired shape.

With reference to FIG. 6 , the fourth configuration 10 d forms theopenings 90 in the base film 200 before base film 200 reaches the drum110. The fourth configuration 10 d also forms the openings 90 at thepre-fill stage. The laser 410 may form openings 90 in the base film 200that forms the packet 50. The laser 410 may be positioned to formopenings 90 in the base film 200 before the base film 200 reaches thedrum 110. The laser 410 is positioned proximate to the base film supplyroll 220. As the sheet of the base film 200 is unrolled and directed tothe drum 110, the laser 410 may form the openings 90. One or more lasers410 may be configured to intermittently form openings 90 in the entirewidth of the base film 200 used to cover the cavities 130. In thisaspect, the openings 90 are formed before the product 60 is added to thebase film 200 and before the base film 200 and the lid film 300 arcscaled together. The openings 90 may be formed in portions of the basefilm 200 which will become the sides or a periphery of the finishedwater soluble packet 50. These areas of the base film 200 are subjectedto less stretching than the areas of the base film 200 film which willbecome the central portions of the water soluble packet 50. By formingthe openings 90 at the sides or periphery, the openings 90 are notgenerally stretched during the filling process, and the openings 90maintain their desired shape.

The laser 410 will now be described. The laser 410 forms one or moreopenings 90 in the water soluble packet 50 or the portion of the films200 and 300 forming the water soluble packet 50. In some aspects, thelaser 410 forms four openings 90 in each water soluble packet 50. Theopenings 90 may have various sizes and shapes. For example, the openings90 may have a size up to approximately 1000 um.

The system 10, laser assembly 400, and/or the processes described hereinmay be incorporated into water soluble packet forming systems andequipment from Cloud Packaging Solutions of Des Plaines, Illinois. Suchequipment is commercially available under the tradename HYDRO-FORMA.

The laser 410 may be configured to provide enough power to generallyonly burn the openings 90 into the film, and, in post-fill applications,not to burn a significant amount of the product 60 therein. The pulseswill not damage the cavities 130, belts, rollers, or other components ofthe water soluble packet forming system 10. Although the laser 410 willnot hurt a worker with incidental, momentary exposure to the laser 410,the system 10 and its equipment may be provided with a protective shieldand/or barriers to prevent accidental exposure of workers to the laser410.

With reference to FIG. 1 , the laser assembly 400 includes the laser 410to form the openings 90 in the water soluble packets 50. The laserassembly 400 also includes the controller 420 and the encoder 430.Existing water soluble packet forming systems may be retrofitted toinclude the laser assembly 400. The laser 410 may be electronicallylinked to the controller 420, which registers the pulses from the laser410 with the moving films 200 and/or 300 or moving water soluble packets50. The encoder 430 may measure the speed of the take away conveyor 190,the drum 120, or any of the films 200 and 300. The encoder 430 is inelectrical communication with the controller 420 to provide thecontroller 420 with data regarding the speed. The laser 410 may bepositioned stationary with respect to the moving films 200 and/or 300 orthe belts carrying the water soluble packets 50. The controller 420 maytime the laser 410 to intermittently pulse the laser 410 as the films200 and/or 300 or the water soluble packets 50 move past a focus pointof the laser 410. The controller 420 may be electronically linked tosensors or additional encoders that monitor the movement of the film orthe belt carrying the water soluble packets 50. The controller 420 timesthe pulses from the laser 410 to impact the films or water solublepackets 50 at the appropriate interval.

Any of a variety of lasers may be used with the system 10 and theprocesses described herein. One suitable laser for the laser 410 is acommercially available laser as Model 3320 from Videoj et Technologies,Inc. of Wood Dale, Illinois. This laser is a 30 watt CO2 laser.

The laser 410 and/or the controller 420 may be programmed to modulateany of a number of parameters and attributes of the laser pulses, forexample, the timing of the laser pulses, the frequency of the laserpulses, the shape of the laser pulse, the pattern of the laser pulses,the area of coverage of the laser pulses, etc. The laser 410 and/or thecontroller 420 may include user-input controls, such as a touch screen,keyboard, etc.

The laser 410 may simultaneously emit an array of pulses thatsimultaneously forms multiple openings 90. For example, the laser 410may be configured to simultaneously form openings 90 in the base film200 covering multiple rows 142 and groups 144 of the cavities 130 of thedrum 110. The laser 410 may be configured to simultaneously formopenings 90 in multiple packets 50, multiple rows of packets 50, and/oror multiple groups 144 of packets 50. Likewise, the laser 410 may beconfigured to simultaneously form openings 90 across a web of the films200 and 300 in multiple columns and rows. For example, in a post-fillprocess, the laser 410 may be configured to simultaneously form openings90 in approximately 12 water soluble packets 50. For example, in apre-fill process, the laser 410 may be configured to simultaneously formopenings 90 across a portion of the films 200 and/or 300 ofapproximately 24 inches wide by approximately 0.25 to 1 inches deep. Forexample, in a pre-fill process, the laser 410 may be configured tosimultaneously form openings 90 in a base film 200 coveringapproximately 12 cavities of the drum 110. Further, multiple lasers 410may be used together to fully cover a width of the drum 110, films 200and/or 300, or the take away conveyor 190.

The lid film 300 and base film 200 may be a water soluble film, such asa polyvinyl alcohol (PVA) film. The films dissolve with contact of wateror other fluids. The films may have a thickness of approximately 1millimeter to approximately 5 millimeter. Such films are commerciallyavailable from Monosol of Merrillville, Indiana. Other water solublefilms for forming the water soluble packets 50 may include anywater-soluble, film-forming polymer, copolymer, or mixtures of suchpolymers. The polymers may include vinyl polymers, includinghomopolymers and copolymers, having functionality rendering the polymerswater-soluble, such as hydroxyl and carboxyl groups. Typicalwater-soluble polymers include at least one of polyvinyl alcohol,partially hydrolyzed polyvinyl acetate, polyvinyl pyrrolidone, alkylcelluloses such as methylcellulose, ethylcellulose, propylcellulose andderivatives thereof, such as the ethers and esters of alkyl celluloses,and acrylic polymers such as water-soluble polyacrylates,polyacrylamides, and acrylic maleic anhydride copolymers. Suitablewater-soluble polymers further include copolymers of hydrolyzed vinylalcohol and a nonhydrolyzable anionic comonomer.

Although the methods, systems, and assemblies described above aredescribed with respect to laundry and dishwashing water soluble packets,the methods, the system 10, and/or the laser assembly 400 may be used toform water soluble packets 50 containing any of a variety of products 60such as, for example, powders, granules, or other solid compositions forany application, such as, for example, herbicides, fertilizers, lawnchemicals, rinse-aids, cleaners, etc. Generally, the water solublepackets 50 will contain a dry product 60.

In addition to the packet forming assembly 100, one or more lasers mayalso be used with or integrated into horizontal form fill seal machinesand/or vertical form fill seal machines in order form openings to ventthe water soluble packets. Horizontal form fill seal machines andvertical form fill seal machines are also used to make water solublepackets. As with other aspects, the openings provide for the escape orrelease of air trapped in the water soluble packets. The laser alsoforms the openings to assist in the filling of the water soluble packetwith detergent or other product. These aspects are shown in FIGS. 9 and10 .

FIG. 9 is a schematic view of a laser-assisted water soluble packetforming system 500 using one or more of lasers 505 a, 505 b, 505 c, 505d, and 505 e with a horizontal form fill seal machine 510. The system500 includes an endless belt 515 operatively engaged to a motor 517 formovement of the endless belt 515. The packet forming assembly 500 alsoforms the water soluble packets 50. The endless belt 515 includes aplurality of cavities 525. A bulk amount of the product 60 is placed ina feed hopper 550, which is generally positioned above the endless belt515. As the endless belt 515 moves, the feed hopper 550 meters an amountof the product 60 into the cavities 525 on top of a base film 520. A lidfilm 530 is sealed to the base film 520, and the water soluble packets50 are separated. The base film 520 is directed to the endless belt 515from a base film supply roll 560. A base film roller 565 presses thebase film 520 against the endless belt 515. The lid film 530 is directedto the endless belt 515 from a lid film supply roll 570. A lid filmroller 575 presses the lid film 530 against the base film 520. Theendless belt 515 includes multiple rows of the cavities 525. Generally,a surface 518 of the endless belt 515 is covered with the cavities 525.The cavities 525 include a vacuum opening 533 that is in fluidiccommunication with a vacuum passage 536. The packet forming assembly 500includes a cutting assembly 580 to separate the water soluble packets 50from each other. The cutting assembly 580 may include a vertical cutter583 to make vertical separation cuts and a horizontal cutter 586 to makehorizontal separation cuts. After the water soluble packets 50 areseparated, the endless belt 515 drops the water soluble packets 50 ontoa take away conveyor 590.

The lasers 505 a, 505 b, 505 c, 505 d, and 505 e may be integrated withthe packet forming assembly 500 in any of a variety of configurations orpositions. Although FIG. 9 shows the use of multiple lasers, only one ofthe lasers 505 a, 505 b, 505 c, 505 d, and 505 e needs to be employed.The lasers 505 a, 505 b, 505 c, 505 d, and 505 e may form the openings90, shown in FIG. 7 , at a pre-fill stage or a post-fill stage in thepacket forming process. Of course, one or more of the lasers 505 a, 505b, 505 c, 505 d, and 505 e may be simultaneously employed at any of theconfigurations or positions. For example, the laser 505 a may form theopenings 90 in the base film 520 before the base film 520 reaches theendless belt 515. The laser 505 b may form the openings 90 when the basefilm 520 is over or drawn into the cavities 525. The laser 505 c mayform the openings 90 in the lid film 530 before the lid film 530 issealed to the base film 520. The laser 505 d may form the openings 90after the water soluble packets 50 are formed on the endless belt 515but before the packets 50 are separated by the cutting assembly 580. Thelaser 505 e may form the openings 90 after the water soluble packets 50are formed on the endless belt 515, separated by the cutting assembly580, and deposited on the take away conveyor 590. The laser 505 e may bepositioned directly over the take away conveyor 590.

FIG. 10 is a perspective view of a laser-assisted water soluble packetforming system 600 using one or both of lasers 605 a and 605 b with avertical form fill seal machine 610. The packet forming assembly 600generally forms water soluble packets 55 from a single layer of a film650. A bulk amount of the product 60 is placed in a feed hopper 610,which is generally positioned above a horn 620. The horn 620 includes anentrance opening 623 and an exit opening 626. The horn 620 also includesan exterior surface 630. Drive rollers 640 pull the film 650 over theexterior surface 630 while the product 60 is metered into an interior ofthe horn 620 through the entrance opening 623. The film 650 is providedby a supply roller 655. A first sealing device 660 seals opposingvertical edges 652 and 654 of the film 650. A second sealing device 670seals the other seams. A cutting device 680 separates the individualpackets 50 and drops the packets 50 onto a take-away conveyor 690.

The lasers 605 a and 605 b may be integrated with the packet formingassembly 600 in any of a variety of configurations or positions.Although FIG. 10 shows the use of multiple lasers, only one of thelasers 605 a and 605 b needs to be employed. The lasers 605 a and 605 bmay form openings 91 in the packets 55 at a pre-fill stage or apost-fill stage in the packet forming process. For example, the laser605 a may form the openings 91 in the film 650 before the film 650reaches the horn 620. For example, the laser 605 b may form the openings91 in the packets 55 on the take-away conveyor 690. The laser 605 b maybe positioned directly over the take-away conveyor 690.

The systems 500 and 600 may also include the controller 420 to programand/or modulate any of a number of parameters and attributes of thelaser pulses. The systems 500 and 600 may also include the encoder 430to register and time the pulses from the lasers to strike the films orpackets at the appropriate interval and time.

We claim:
 1. A system for forming openings in water soluble packets,comprising: a packet forming assembly which forms water soluble packetshaving a base film and a lid film containing a product, wherein thepacket forming assembly includes one or more cavities, wherein a basefilm supply roll supplies the base film to cover the one or morecavities, wherein the one or more cavities include vacuum openings influidic communication with a vacuum assembly by a vacuum passage,wherein the vacuum assembly draws or stretches a portion of the basefilm into the one or more cavities, wherein a feed hopper meters anamount of the product into the one or more cavities over the base film,wherein a lid film supply roll supplies the lid film, and wherein thelid film is sealed to the base film; and a laser which forms one or moreopenings in the base film of the water soluble packets, the laserfocused at the one or more cavities, and wherein the laser is configuredto form the one or more openings in the portion of the base film afterit is drawn or stretched into the one or more cavities to form areceptacle shape in the one or more cavities to receive the product andbefore the feed hopper meters the amount of product into the base filmpositioned in the cavities.
 2. The system according to claim 1, whereinthe laser is positioned proximate to the one or more cavities, andwherein the laser is configured to form a plurality of openings arrangedin a non-linear pattern in the portion of the base film after theportion of the base film is drawn or stretched into the one or morecavities.
 3. The system according to claim 1, wherein the laser isconfigured to form the one or more openings in the portion of the basefilm after the portion of the base film is drawn or stretched into theone or more cavities.
 4. The system according to claim 1, wherein thelaser is configured to form the one or more openings in the portion ofthe base film before the feed hopper meters the amount of the productinto the one or more cavities, wherein each opening has a size up toapproximately 1000 um.
 5. The system according to claim 1, wherein thepacket forming assembly is a rotary drum machine comprising a drumhaving the one or more cavities.
 6. The system according to claim 1,wherein the packet forming assembly is a horizontal form fill sealmachine.
 7. The system according to claim 1, wherein the product is apowder detergent or a granule detergent.
 8. The system according toclaim 5, further comprising a controller which controls pulses from thelaser.
 9. The system according to claim 8, further comprising anencoder, wherein the encoder measures or senses a movement of the drumin order to register the pulses of the laser with the base film.
 10. Asystem for forming openings in water soluble packets, comprising: arotating drum operatively engaged to a motor for rotating the drum, thedrum comprising one or more cavities; a base film supply roll whichsupplies a base film to the drum to cover the one or more cavities; afeed hopper which meters an amount of a product into the one or morecavities over the base film; a lid film supply roll which supplies a lidfilm to the drum; and a laser which forms one or more openings in thebase film, the laser positioned proximate to the rotating drum, thelaser focused at the one or more cavities; wherein each of the one ormore cavities includes a vacuum opening that is in fluidic communicationwith a vacuum passage, and a vacuum assembly of the rotary drum drawsair through the vacuum opening and draws or stretches a portion of thebase film into the one or more cavities, and wherein the laser isconfigured to form the one or more openings in the portion of the basefilm after the base film is drawn or stretched into the one or morecavities to form a receptacle shape in the one or more cavities toreceive the product and before the feed hopper meters the amount ofproduct into the base film positioned in the cavities.
 11. The systemaccording to claim 10, wherein the laser simultaneously pulses the basefilm after portions of the base film are drawn or stretched into one ormore rows of the one or more cavities.
 12. The system according to claim10, further comprising an encoder, wherein the encoder measures orsenses a movement of the drum in order to register pulses of the laserwith the base film.
 13. The system according to claim 10, wherein thelaser is positioned between the feed hopper and the locus where aportion of the base film is drawn or stretched into the one or morecavities.
 14. A system for making water soluble packets, comprising: apacket forming assembly comprising a rotary drum which forms watersoluble packets having a base film and a lid film containing a product,wherein the rotary drum includes one or more cavities, wherein a basefilm supply roll supplies the base film to cover the one or morecavities, wherein a feed hopper meters an amount of the product into theone or more cavities over the base film, wherein a lid film supply rollsupplies the lid film, and wherein the lid film is sealed to the basefilm, wherein each of the one or more cavities includes a vacuum openingthat is in fluidic communication with a vacuum passage, and a vacuumassembly of the rotary drum draws air through the vacuum opening to drawor stretch a portion of the base film into the one or more cavities andto line the one or more cavities with the portion of the base film; anda laser which makes one or more openings in the base film of the watersoluble packets, the laser directed at the portion of the base filmlining the one or more cavities to form a receptacle shape in the one ormore cavities to receive the product and before the feed hopper metersthe amount of product into the base film positioned in the cavities. 15.The system for making water soluble packets according to claim 14,wherein the vacuum assembly draws or stretches the portion of the basefilm into the one or more cavities, wherein the laser is configured tomake the one or more openings in the portion of the base film while theportion of the base film lines the one or more cavities to form thereceptacle shape in the one or more cavities.
 16. The system for makingwater soluble packets according to claim 14, wherein the vacuum assemblydraws or stretches the portion of the base film into the one or morecavities, wherein the laser is configured to make a plurality ofopenings arranged in a non-linear pattern in the portion of the basefilm after the portion of the base film is drawn or stretched into theone or more cavities.
 17. The system for making water soluble packetsaccording to claim 14, wherein the laser is configured to make the oneor more openings in the portion of the base film before the feed hoppermeters the amount of the product into the one or more cavities, whereineach opening has a size up to approximately 1000 um.
 18. The system formaking water soluble packets according to claim 14, further comprisingan encoder, wherein the encoder measures or senses a movement of therotary drum in order to register pulses of the laser with the base film.19. The system for making water soluble packets according to claim 14,wherein the laser is positioned between the feed hopper and the locuswhere a portion of the base film is drawn or stretched into the one ormore cavities.
 20. The system for making water soluble packets accordingto claim 14, further comprising a controller, wherein the controllermodulates pulses from the laser to direct the pulses at the portion ofthe base film lining the one or more cavities.
 21. The system for makingwater soluble packets according to claim 20, comprising an encoder orsensor, wherein the encoder or sensor is in electrical communicationwith the controller, and the encoder or sensor measures or senses amovement of the rotary drum in order to register the pulses of the laserwith the portion of the base film lining the one or more cavities. 22.The system for making water soluble packets according to claim 14,wherein the laser is positioned between the feed hopper and the basefilm supply roll after an application of the base film into the one ormore cavities.
 23. A system for making water soluble packets,comprising: a horizontal form, fill and seal machine operatively engagedto a motor for advancing a continuous belt the horizontal form, fill,and seal machine comprising one or more cavities; a base film supplyroll which supplies a base film to the horizontal form, fill and sealmachine to cover the one or more cavities; a vacuum assembly, whereinthe one or more cavities are in fluidic communication with the vacuumassembly, wherein the one or more cavities include vacuum openings influidic communication with the vacuum assembly by a vacuum passage,wherein the vacuum assembly draws or stretches a portion of the basefilm into the one or more cavities to line the one or more cavities withthe portion of the base film; a feed hopper which meters an amount of aproduct into the one or more cavities over the base film; a lid filmsupply roll which supplies a lid film to the horizontal form, fill andseal machine; and a laser which makes openings in the base film, whereinthe laser is positioned proximate to the horizontal form, fill and sealmachine between the feed hopper and the base film supply roll, the laserconfigured to make the openings in the portion of the base film whilethe portion of the base film lines the one or more cavities to form areceptacle shape in the one or more cavities to receive the product andbefore the feed hopper meters the amount of product into the base filmpositioned in the cavities.
 24. The system according to claim 1, whereinthe laser comprises a 30 watt CO₂ laser.
 25. The system according toclaim 10, wherein the laser comprises a 30 watt CO₂ laser.
 26. Thesystem for making water soluble packets according to claim 23, whereinthe laser comprises a 30 watt CO₂ laser.